U.S. patent application number 15/899264 was filed with the patent office on 2018-07-12 for resistive bypass for series lighting circuit.
The applicant listed for this patent is Seasonal Specialties, LLC. Invention is credited to Steven J. Altamura.
Application Number | 20180199419 15/899264 |
Document ID | / |
Family ID | 39732618 |
Filed Date | 2018-07-12 |
United States Patent
Application |
20180199419 |
Kind Code |
A1 |
Altamura; Steven J. |
July 12, 2018 |
RESISTIVE BYPASS FOR SERIES LIGHTING CIRCUIT
Abstract
A resistor bypass circuit for a series lighting circuit includes
a plurality of serially connected light sources and a bypass
resistor being connected in parallel with at least one of the
respective light sources, each respective light source being low
wattage and being capable operating on a one hundred percent duty
cycle as desired.
Inventors: |
Altamura; Steven J.;
(Scarsdale, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Seasonal Specialties, LLC |
Eden Prairie |
MN |
US |
|
|
Family ID: |
39732618 |
Appl. No.: |
15/899264 |
Filed: |
February 19, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14840705 |
Aug 31, 2015 |
9900968 |
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15899264 |
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14052124 |
Oct 11, 2013 |
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14840705 |
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12947488 |
Nov 16, 2010 |
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14052124 |
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11962964 |
Dec 21, 2007 |
7851981 |
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12947488 |
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60876868 |
Dec 22, 2006 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01J 9/00 20130101; H01K
3/00 20130101; H05B 39/041 20130101; H05B 47/23 20200101 |
International
Class: |
H05B 39/04 20060101
H05B039/04; H01J 9/00 20060101 H01J009/00; H01K 3/00 20060101
H01K003/00; H05B 37/03 20060101 H05B037/03 |
Claims
1. A resistor bypass circuit for a series lighting circuit
comprising a plurality of serially connected light sources and a
bypass resistor being connected in parallel with at least one of
the respective light sources, each respective light source low
wattage and being capable operating on a one hundred percent duty
cycle as desired.
2. The resistor bypass circuit of claim 1, where the circuit is
series-parallel connected.
3. The resistor bypass circuit of claim 1, the light source being
an incandescent bulb.
4. The resistor bypass circuit of claim 1, the light source being a
semiconductor
5. The resistor bypass circuit of claim 1, the light source being
an LED.
6. The resistor bypass circuit of claim 4, the light source the
semiconductor light source providing a twinkling effect.
7. The resistor bypass circuit of claim 6, the semiconductor light
source utilizing electronic circuits that control the flashing rate
of the light source, which would only affect the individual
lighting element as the resistive bypass would allow current to
continue to flow in remaining lighting elements in the series
circuit.
8. The resistor bypass circuit of claim 6, the electronic circuits
being LED packages that incorporate integrated circuits (ICs)
9. The resistor bypass circuit of claim 5, the light source being a
semiconductor light source for providing color changing
characteristics.
10. The resistor bypass circuit of claim 9, the semiconductor light
source utilizing LED packages that incorporate two or more LED
chips, and an integrated circuit (IC), the integrated circuit
controlling each LED chip in respective LED packages
independently.
11. The resistor bypass circuit of claim 10, the IC controlling the
current and/or voltage to the individual LED chips in the LED
package, the control providing for the mixing of the LED chip
colors to get various resultant colors.
12. The resistor bypass circuit of claim 11, the control only
affecting individual lighting element, the bypass resistor
providing for current continuing to flow in remaining lighting
elements in the series circuit.
13. The resistor bypass circuit of claim 1, a respective resistive
bypass resistor being connected in parallel with more than one
light source, the failure of one of the light sources thereby only
affecting a limited number of the plurality of light sources.
14. The resistor bypass circuit of claim 1 being utilized in AC or
DC circuits powered form a power source selected from the list
consisting of batteries, step down transformers, AC utility power,
or converters from AC to DC or DC to AC power, pulsed DC, and
filtered or unfiltered DC, or partially filtered AC.
15. A resistor bypass circuit for a series lighting circuit
comprising a plurality of serially connected incandescent light
sources and a bypass resistor being connected in parallel with at
least one of the respective light sources, each respective light
source being low wattage when conducting and being capable
operating on a one hundred percent duty cycle as desired.
16. The resistor bypass circuit of claim 15, where the circuit is
series-parallel connected.
17.-25. (cancelled)
Description
RELATED APPLICATIONS
[0001] The present invention claims the benefit of U.S. Provisional
Application 60/876,868, filed on Dec. 22, 2006, incorporated herein
in its entirety by reference.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention is generally related to an improved
light circuit for series circuits or series-parallel circuits
utilizing incandescent, LED, or other types of lighting sources,
and more particularly, the present invention relates to a resistive
bypass element that will continue to conduct electricity and keep
the remainder of the series circuit of lights lit even when one or
more individual lighting elements are burnt out, defective, broken,
have a loose connection or a broken connection in the series
circuit, including series parallel circuits.
BACKGROUND OF THE INVENTION
[0003] Series connected circuits containing lighting sources are
well known especially in lighting strings and flexible lighting
(Rope Lights) around the holidays when such light strings are used
for decorative purposes. More recently, series connected lighting
sources are becoming popular in task lighting, general
illumination, automotive lighting, and specialty lighting utilizing
LEDs. Generally, the lights in these lighting circuits are
electrically in series rather than in parallel. One particular
drawback to these types of lighting circuits is that when a
lighting source is removed from the circuit, is burnt out,
defective, or has a loose connection, the entire lighting circuit
is rendered inoperable. Each lighting element within the circuit
completes the electrical circuit, so when a light source is removed
(for a replaceable type), a connection becomes loose, or the
lighting element burns out or other lighting component within the
light source, a gap is created in the circuit and electricity is
unable to continue to flow through the circuit. When a "good" light
source is inserted into the circuit or socket, it completes the
circuit, thus allowing electricity to flow uninterrupted.
[0004] Specifically, Fisherman, U.S. Pat. No. 2,760,120, discloses
a series circuit for a light set with individual incandescent
flasher or twinkle bulbs that include a bypass resistor in parallel
with the bulb element. The operation of the Fisherman light set is
limited to a set with a bulb that flashes on and off, a duty cycle
of less than 100%. The on time of the bulb is necessary to control
heat generation in the resistor, the resistor conducting during the
off time of the bulb, thereby regulating the heat produced in the
resistor circuit. The Fisherman device cannot be applied to a set
wherein a bulb is burnt out, removed, or loose (and not conducting)
to continue to illuminate the remaining bulbs in the circuit. In
such situation, the bypass resistor is continually conducting and
the temperatures generated on any bypass resistor of practical size
(let alone one that fits into a socket) will far exceed ignition
temperatures of near by materials used in construction of the set.
Further, the Fisherman bulb is a high energy bulb, being 8 volt and
1/4 amp, for a power consumption of 2 watts. A more energy
efficient bulb is in demand at the present time. Presently, bulbs,
such as that depicted generally at 500 in prior art FIG. 15, are
utilized. Such bulbs are a considerable improvement when compared
to the Fisherman bulb, having 0.35-0.425 watt power consumption.
There is still a need in the industry for a more energy efficient
bulb.
[0005] While previous mechanical and electrical circuit
configurations have been used in an attempt to address the problems
described above, none do so with the reliability, simplicity, low
cost of the present invention, and reduced energy consumption. The
difficulties and drawbacks of previous lighting series circuit
configurations are overcome by the resistive bypass for a series
light circuit of the present invention.
SUMMARY OF THE INVENTION
[0006] The systems and methods of the invention have several
features, no single one of which is solely responsible for its
desirable attributes. Without limiting the scope of the invention
as expressed by the claims which follow, its more prominent
features will now be discussed briefly. After considering this
discussion, and particularly after reading the section entitled
"Detailed Description of the Drawings" one will understand how the
features of the light unit for a light string provide several
advantages over traditional series light circuit.
[0007] Accordingly, it is an object of the present invention to
provide a novel and improved bypass circuit for a series light
circuit configuration capable of keeping uninterrupted current flow
on condition that a light source of the circuit is removed, becomes
loose, fails to conduct, or lighting element or other lighting
device of the light source burns out, or becomes defective within
the light source.
[0008] A further object of the present invention is to provide an
incandescent bulb of reduced energy consumption while at the same
time maintaining the level of brightness apparent to the human eye
as is produced by current higher energy consuming bulbs (the
standard bulb having a power consumption of 0.35-0.425 watts). The
present invention utilizes bulbs that are less than 0.25 watts and
are more preferably 0.20 watts. In order to achieve substantially
the same brightness as the standard bulb, the bulb of the present
invention uses a higher purity tungsten filament, along with a
tighter coil for the filament when rated 0.20 watts. Further, to
improve the brightness, the filament is placed higher into the bulb
canopy, so that losses from the plastic bulb adaptor at the bottom
of the bulb do not absorb as much light. This provides for a
measurably brighter bulb, and also provides to the human eye an
even apparently brighter bulb, as the filament is higher up into
the bulb, something that hasn't been done in the industry to date.
Such bulbs can be utilized with a duty cycle of 100% and, when
disabled, the conducting bypass resistor in the circuit of the
present invention does not achieve dangerous temperature levels due
to the reduced current flow. The Fisherman device is necessarily
restricted to employment with flasher bulbs, and these must be used
in a set where the bulbs are never fully off (disabled) so that the
bypass resistor is not continually conducting.
[0009] Another object of the present invention is to provide the
ability to allow for semiconductor light sources, such as light
emitting diodes (LEDs), to provide a twinkling affect, by utilizing
LED packages that incorporate integrated circuits (ICs) or other
types of electronic circuits that control the flashing rate of the
light source, which would only effect the individual lighting
element as the resistive bypass would allow current to continue to
flow in remaining lighting elements in the series circuit. In
another embodiment of the invention, one or more semiconductor
light sources, each with a flashing circuit, but without an
associated bypass element in parallel, can be located in the
lighting circuit in order to flash all the remaining light sources
in the series circuit.
[0010] In yet another embodiment of the invention, one or more
incandescent light sources, each with a flashing device, but
without an associated bypass element in parallel, can be located in
the lighting circuit in order to flash all the remaining light
sources in the circuit.
[0011] Yet another object of the present invention is to provide
the ability to allow for semiconductor light sources, such as LEDs,
to provide color changing characteristics by utilizing LED packages
that incorporate two or more LED chips, and an IC, or other
electronic circuit, that controls each LED chip in the LED package
independently, while the electronic circuit or IC controls the
current and/or voltage to the individual LEDs in the LED package,
allowing for the mixing of the LED chip colors to get various
resultant colors, which would only affect the individual lighting
element as the resistive bypass would allow current to continue to
flow in remaining lighting elements in the series circuit. Those
skilled in the art would also recognize that a zener diode could be
used in parallel to the light source and bypass circuit to help
regulate the voltage across the light source.
[0012] Further objects and features of the invention will be
readily apparent to those skilled in the art from the following
specification which includes the appended claims and drawings.
[0013] To achieve the above objects and in accordance with the
purpose of the invention, as embodied and broadly described herein,
one embodiment of a light circuit for a series lighting circuit of
the present invention comprises lighting sources connected in
series with each other, where each lighting source has a resistive
bypass element connected in parallel across it.
[0014] The embodiment of this device is to provide a low cost
resistive bypass element for series connected light sources. The
current movement towards low energy incandescent bulbs, LEDs, and
other energy saving light sources allows for a simple resistor to
be utilized without creating the heating issues previously faced if
such a device was attempted. Now with these low power consuming
lighting sources, a resistive bypass element becomes the forefront
of products, providing a low-cost bypass circuit.
[0015] In addition, the use of the resistive bypass element in
series connected lighting circuits enables longevity and durability
to continue without affect from the failure of any single light
source due to defect, or connection issues.
[0016] In another embodiment of the present invention, the
resistive bypass element may be connected in parallel with more
than one light source, where the failure of one bulb would then
only affect a limited amount of light sources in the lighting
circuit, further saving the cost of bypass resistive elements
across each lighting source.
[0017] In another embodiment of the present invention, a resistive
bypass circuit allows for other types of lighting effects, such as
twinkle type products where a semiconductor light source can
utilize miniature ICs inside a lighting package, and will only
affect that lighting source, allowing the remaining light sources
to function independently. Also, more than one light package may
have the twinkling effect. For this embodiment, the resistive
bypass may only be used across those twinkling effect light
sources, as an additional embodiment, or may be used across all
lighting sources.
[0018] One more embodiment of the resistive bypass circuit is that
it also allows for the use of color changing LED packages, that
utilize more than one LED chip inside, and may consist of an IC
controlled mixing of the LED chips to create other resultant
colors, and will only effect that lighting source, allowing the
remaining light sources to function independently. Also, more than
one light package may have this color changing effect. For this
embodiment, the resistive bypass may only be used across those
color changing light sources, as an additional embodiment, or may
be used across all lighting sources.
[0019] The series circuits above with bypass resistors, can also be
employed in series--parallel circuits, and be employed in products
with or without lampholders, including directly connected to
printed circuit boards, as other embodiments of the invention.
[0020] The present invention has numerous features and advantages
associated therewith.
[0021] The bypass circuit of the present invention herein described
has an advantage of keeping the remainder of lights within a series
lighting circuit lit when a light source is missing from, or
becomes loose in, one or more light source sockets or circuits, or
becomes defective. This is accomplished by continuing to conduct
electricity through the series light circuit even when a light
source is broken, loose, poor connection, or defective light
source.
[0022] The bypass circuit can be utilized in AC or DC circuits
powered by batteries, step down transformers, AC utility power, or
converters from AC to DC or DC to AC power, pulsed DC, and filtered
or unfiltered DC.
[0023] As will be realized, the invention is capable of other and
different embodiments and its several details are capable of
modifications in various respects, all without departing from the
invention. Accordingly, the drawing and description are to be
regarded as illustrative and not restrictive.
[0024] Other objects, advantages and novel features of the present
invention will be drawn from the following detailed description of
preferred embodiment of the present invention with the attached
drawings. The accompanying drawings are included to provide a
further understanding of the invention, and are incorporated in and
constitute a part of this specification. The drawings illustrate
embodiments of the invention and, together with the description,
serve to explain the principles of the invention, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a circuit diagram of one embodiment of the present
invention where the lighting sources are incandescent bulbs;
[0026] FIG. 2 is a circuit diagram of one embodiment of the present
invention where the lighting sources include LEDs;
[0027] FIGS. 2a-2c show various configurations and locations of the
current limiting resistor and series and series-parallel
configurations of FIG. 2;
[0028] FIG. 2D shows a circuit diagram of one embodiment using a
full wave rectifier with an optional filter capacitor;
[0029] FIG. 3 is a diagram of a light string embodiment of the
present invention where the lighting sources are incandescent bulbs
and the lighting element is a filament;
[0030] FIG. 4a is a front and side view of a light source assembly
where the light source is an incandescent bulb;
[0031] FIG. 4b is a front and side view of a light source assembly
that includes an incandescent light bulb and a resistor;
[0032] FIG. 4c is a front and side view of a light source assembly
that includes an incandescent light bulb, a resistor, and a
large-diameter lamp holder;
[0033] FIG. 4d is a front and side view of a light source assembly
showing the brass contacts of the light source assembly and an
alternate resistor mounting position;
[0034] FIG. 5 is a diagram of a light string embodiment of the
present invention where the light sources LEDs and the lighting
element is an LED semiconductor chip;
[0035] FIG. 6 is a front view of a light source assembly where the
light source includes an LED encased in an epoxy lens;
[0036] FIG. 7 is a diagram of one embodiment of the present
invention that produces a twinkling effect and includes a split
construction of a full wave rectifier;
[0037] FIG. 8 is diagram of another embodiment of the present
invention that produces a twinkling effect and includes traditional
full-wave rectification;
[0038] FIG. 9 is a front and close-up view of the present invention
embodied in a wire tree branch;
[0039] FIG. 10 is a front view of a needless artificial tree as
used in a lighted green goods system of the present invention;
[0040] FIG. 11 is a front view of an artificial tree with needles
as used in a lighted green goods system of the present
invention;
[0041] FIG. 12 is a front view of one embodiment of a lighted green
goods system using bypass circuit light strings;
[0042] FIG. 13 is a view of a flexible lighting system with a
bypass circuit using incandescent light sources;
[0043] FIG. 14 is a view of a flexible lighting system with a
bypass circuit using LED light sources;
[0044] FIG. 15 is an elevational view of a prior art bulb;
[0045] FIG. 16 is an elevational view of a bulb of the present
invention; and
[0046] FIG. 17 is an elevational view of a bulb of a further
embodiment of the present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
[0047] The resistive bypass circuit 10, being a set or sting of
lights, as shown in FIG. 1 includes a power source 12, light
sources 14, and bypass resistors 16. Power source 12 is shown in
FIG. 1 is a 120 volt alternating current (AC) power source, power
source can be any voltage AC, direct current (DC), AC converted to
DC, or DC converted to AC, both filtered or unfiltered DC, and
pulsating DC or any other power source that can power the lighting
sources. Light sources 14 may include incandescent bulbs, LEDs, or
other lighting devices. Light sources 14 of FIG. 1 are incandescent
bulbs.
[0048] Bypass resistors 16 are configured in parallel with light
sources 14, and combinations of bypass resistors 16 and light
sources 14 are configured in series. Light sources 14 and bypass
resistors 16 may be packaged together into light source assemblies
18. When all light sources 14 are operating properly, a portion of
the total current flowing through bypass circuit 10 flows through
light source 14, while the remainder flows through bypass resistor
16.
[0049] In the event that a light source 14 ceases to conduct, and
current flow is interrupted through that light source 14, the total
current will flow through its corresponding bypass resistor 16. A
missing, broken, or improperly connected light source 14 may cause
a light source 14 to fail to conduct. In the case where light
source 14 is an incandescent bulb, filament failure, or burnout,
may be the cause of a light source failing to conduct. Without
bypass resistors 16 operating in parallel with light sources 14,
any failure in a light source 14 would interrupt power to all other
light sources 14. The values of bypass resistors 16 are typically
the same, and are chosen such that an appropriate current flows
through light sources 14 when all light sources are operating
properly.
[0050] FIG. 2 illustrates another embodiment of the present
invention that uses LEDs as a light source. Resistive bypass
circuit 20 includes power source 12, light sources 26, optional
current limiting resistors 24, and bypass resistor 28. Light
sources 26, optional current limiting resistors 24, and bypass
resistors 28 may be packaged together into light source assemblies
22. In the embodiment shown in FIG. 2, light source 26 is a single
LED, preferably of equal to or less than 0.25 W. In other
embodiments, light source 26 may be an LED chip that includes more
than one LED. Those skilled-in-the-art will appreciate that the
value of current limiting resistors 24 will be chosen based on the
type of light source 26, the number of light sources 26, the number
of bypass resistors 24, and the number and value of bypass
resistors 28.
[0051] In the embodiment shown in FIG. 2, power source 12 provides
power to bypass circuit 20. When all light sources 26 are operable,
current flows through the circuit, with a portion of the total
current flows through the path containing current limiting resistor
24 and light source 26, while the remainder flows through bypass
resistor 28. When current flow is interrupted through a light
source 26, total current flows through the corresponding bypass
resistor 28, allowing the remaining light sources 26 to
operate.
[0052] Resistive bypass circuits 10 and 20 may be used with any
series, or series-parallel connected lighting device where failure
of the bulb or its connection will turn off some or all of the
bulbs. This includes mini-bulb lighting strings used for Christmas
and other holiday decorative lighting, rope lights (also known as
flexible lighting) and other general lighting applications that use
series connected lamps or LEDs, such as a LED desk lamp, or
under-counter light.
[0053] Power source 12 is shown in FIG. 2 is a 120 volt alternating
current (AC) power source, power source can be any voltage AC,
direct current (DC), AC converted to DC, or DC converted to AC,
both filtered or unfiltered DC, and pulsating DC, or any other
power source that can power the lighting sources.
[0054] FIGS. 2a-2c show various configurations and locations of the
current limiting resistor and series and series-parallel
configurations of FIG. 2. FIGS. 2a and 2b, show light source
assemblies, 22, that contain only the light source, 26, and the
bypass resistor, 28, with the current limiting resistor located
outside of the light source assembly 22.
[0055] FIG. 2D shows a circuit diagram utilizing a filtered full
wave rectifier, 82 with an optional filter capacitor 84. The full
wave rectifier could be replaced by a single rectifier diode, 76,
to produce 1/2 wave rectification, and can be optionally filtered
by capacitor 84. If a large enough capacitor 84 is selected,
utilizing a single diode, 76, it could simulate full wave
rectification to the circuit.
[0056] It was desired to utilize incandescent bulbs with the
resistive bypass circuit 10 as shown in FIG. 1. In order to make
the resistor set 10 work with modern, high temperature materials,
it was needed to reduce the wattage of the bulbs to at least 0.25 W
(standard bulbs in the industry are either the common 0.425 W bulb,
or the less common 0.35 W bulb, as noted in prior art FIG. 15), but
it is preferable to use 0.20 Watts. Sets using 0.25 W bulbs are on
the edge of passing ANSI/UL standards, a critical condition for
placing such sets in the marketplace. The 0.20 W bulbs, on the
other hand, more safely allow the set to operate, however, either
could be used.
[0057] While the 0.25 W bulbs (2.5V, 100 mA) were close in
brightness to the 0.425 W bulbs (2.5V, 170 mA) that are commonly
used, by using a thinner filament wire or other techniques to
compensate for lumen output, the brightness of the 0.25 watt bulb
is substantially equal to the standard 0.425 bulb. A conventionally
constructed 0.20 W bulb (2.5V, 80 mA) bulb is even dimmer than the
0.35 W bulb (2.5V, 140 mA), and in the holiday market, the market
demands bright bulbs.
[0058] To make up for the shortcomings of a conventionally
constructed 0.20 W bulb, the bulbs of the present invention, noted
generally at 600 in FIGS. 16 and 17, employ a higher purity
tungsten filament, along with a tighter coil of the filament 602.
Further, the filament 602 is disposed higher into the bulb canopy
608 by the dimension H, noted in FIG. 15. The filament 602 is
connected by relatively longer leads 604 than the leads 504 of the
prior art that support the prior art filament 502. An advantage of
such disposition is that losses from the plastic bulb adaptor 606
at the bottom of the bulb 600 did not absorb as much light. Such
disposition of the filament 602 provides for a measurably brighter
bulb 600, and also, as viewed by the human eye, an even brighter
bulb 600 is perceived as compared with the prior art construction
of FIG. 15, as the filament 602 is higher up into the bulb canopy
608, a construction that hasn't been done in the industry.
[0059] Further, to enhance the brilliance of the reduced wattage,
one version of the low energy bulb 600 of the present invention,
the filament 602 is formed of a purer form of tungsten and is of
thinner construction as compared to the prior art bulb 500.
Additionally, the filament 602 is wound tighter than the filament
502 of the prior art. However, one skilled in the art would
recognize that if brighter bulbs were not desired, standard bulb
construction could be utilized.
[0060] In addition, as noted with respect to FIG. 2 above, resistor
sets 10 may be employed with light sources 26 being LEDs. Such LEDs
typically operate at much lower current (20 mA) with a power draw
of 0.08 W or less, and therefore allow for very cool operation of
the resistor bypass circuit 28, even when the bypass resistor 28 is
continually conducting. In either case, there is substantial energy
savings. In another embodiment, higher power LEDs or several LEDs
in parallel may be employed across the bypass resistor.
[0061] The above noted features allow the resistor bypass circuit
10 to operate as a twinkling set by inserting a flasher bulb into
any part of the circuit or, if provided, into a socket socket.
Flasher bulbs are bulbs where a bimetallic strip heats, and open
circuits the bulb (see for example, Fisherman), where a normal
holiday light set that creates a twinkling effect has to use
twinkling bulbs, where when the bimetallic strip is heated by the
filament, it shorts out the bulb, allowing the remaining bulbs to
light. In such sets where the bulbs short, ANSI/UL has very
stringent requirements for construction and operation. In contrast
however, in the resistor bypass set 10 of the present invention,
use of a flasher bulb is not restricted, nor does it pose any
additional safety concerns, as when the flasher bulb open circuits,
it allows the resistor bypass set to work as it would normally, and
actually reduces the current to the remaining bulbs, allowing the
remaining bulbs to run cooler, as compared to the twinkle bulb set
where it operates hotter when one or more bulbs is in the shorted
condition.
[0062] The resistor bypass set 10 also has the advantage of being a
safer set than the standard mini light sets that commonly use a
shunt wire inside the bulb to allow the current to continue
flowing, as sets containing shunted bulbs create short circuits
across the bulb, further dividing the input voltage by the
remaining bulbs, increasing the power drop across each bulb. The
increased power drop increases the surface temperature of the bulb,
and causing the remaining bulbs in the set to burn out faster. This
repeated action causes the bulbs to become very hot, where as the
resistor bypass set 10 of the present invention operates such that
every bulb failure, places a higher resistance into the set than
the bulb it replaces, causing the remaining bulbs to proportionally
dim, causing them to increase their life, and to run cooler.
However, the resistor could be sized such that the current is not
reduced, and may remain relatively constant, or even slightly
increase, depending on the effect desired.
[0063] FIG. 3 is an embodiment of the present invention in the form
of a series-connected decorative light string 30. Decorative light
string 30 includes power plug 32, optional light source assemblies
34, incandescent bulbs 36 and bypass resistors 16. Power plug 32
may directly plug into utility power (120V, 208V, 220V, 240V, 280V,
etc), connect to a step down power supply (such as a Class 2 power
supply) or may be omitted for direct connection to a power source.
As shown in FIG. 3, incandescent bulbs 36 may be a miniature
bulb-type (mini bulb) operating on 2.5 VAC at 70-120 mA, or some
other low current draw bulb. Resistors 16 may be in the range of 30
ohms to 60 ohms, though the value of resistors 16 will vary
according to the total current flow desired, as well as according
to other factors mentioned above. Resistors 16 are configured in
parallel with light sources 36. Light source assemblies 34, if
provided, are configured electrically in series with each other. As
indicated earlier, when a light source assembly 36 fails, total
system current will flow through the corresponding bypass resistor
16, allowing the other light sources 36 to remain lit.
[0064] In one embodiment of the decorative light string 30 includes
one or more light source assemblies 34 that includes a flashing
device, but does not include a bypass element 16 in parallel,
causing all of the remaining light source assemblies 34 in the
series circuit of decorative light string 30 to flash.
[0065] Some methods of making light source assemblies 34 are
further described in FIGS. 4a-d, but the present invention is not
limited to the embodiments depicted in the figures. FIG. 4a
illustrates a light source assembly 34a including a light source
36a in the form of a mini bulb, and a lamp holder 35a. FIG. 4b
illustrates a light source assembly 34b that includes a light
source assembly 34b, a light source 36b in the form of a mini bulb,
a bypass resistor 16, and a lamp holder 35b. Lamp holder 35b may be
larger than lamp holder 35a to accommodate bypass resistor 16.
Bypass resistor 16 is connected across light source 36b in
parallel. The connection may be accomplished by soldering,
crimping, friction fit, compression fit, or other means, including
connecting to a pair of brass contacts (not shown), to the leads of
light source 26b, or to other conductors.
[0066] FIG. 4c illustrates yet another light source assembly, light
source assembly 34c, which includes a light source assembly 34c, a
light source 36c in the form of a mini bulb, a bypass resistor 16,
and a lamp holder 35c. In this embodiment, lamp holder 34c is even
larger than lamp holder 35b.
[0067] FIG. 4d illustrates another light source assembly, light
source assembly 34d, which includes a light source assembly 34d, a
light source 36d in the form of a mini bulb, a bypass resistor 16,
and a lamp holder 35d. In this embodiment, lamp holder 34d may be
longer than lamp holder 35b. In the embodiment shown in FIG. 4, one
lead of bypass resistor 16 can be crimped to the brass contact. The
other lead of bypass resistor 16 may be crimped to a second brass
contact 17, or connected by other means, such that it is
electrically in parallel with light source 36d. Other means
includes being connected to the leads of light source 36. In
addition to crimping, soldering, friction fit, compression, and
other common connection means may be employed.
[0068] In yet another embodiment, light sources 36 may be mini
bulbs filled with an inert gas. Since the use of a bypass resistor
16 has the potential to decrease current flow through light sources
36, an inert gas, such as Krypton, can be used in place of a vacuum
to allow for the bulb filament to burn whiter and maintaining the
same bulb life expected from mini bulbs and get even closer to a
standard mini bulb brightness.
[0069] Lamp holders 35 of light source assemblies 34 may include
molded lamp holders, assembled-on lamp holders, heat-shrink formed
lamp holders, and other types of lamp holders. Light sources 36 may
be removable, or non-replaceable. In another embodiments, the light
source assemblies 34 may by mounted on a rigid or flexible printed
circuit board, or connected directly to conductors or wires.
[0070] Another embodiment of the present invention is a light
string 40 as shown in FIG. 5. Light string 40 includes an optional
power plug 42, light sources 26, current-limiting resistors 24, and
bypass resistors 28. Light sources 26, current limiting resistors
24, and bypass resistors 28 may be packaged together into light
source assemblies 44. The embodiment as shown works substantially
as described above.
[0071] One embodiment of light source 44 is shown in FIG. 6. Lamp
holder base 33 houses bypass resistor 28, brass contacts 17, and
the ends of wires 45. Bypass resistor 28 is connected to brass
contacts 17 or other contact material to create a parallel
configuration. Brass contacts 17 may be crimped on to wires 45 or
other conductors. The optional lamp holder adapter 48 attaches to
epoxy or some other material lens 46. The lens 46 encases light
source 26, where light source 26 in this embodiment is an LED.
[0072] In another embodiment, the bypass resistor 28, may be
located directly across the LED leads 49 outside of any optional
lens material, 46.
[0073] In an alternate embodiment, the bypass resistor 28 may be
located within the LED lens material 46 in parallel with the LED,
or even inside the glass bulb envelope for incandescent bulbs.
[0074] FIG. 7 illustrates another embodiment of the present
invention, light string 50, that utilizes partial rectification and
blinking LEDs inside the epoxy lens. Light string 50 includes a
power plug 52, end connect 53, and light source assemblies 54 and
56. Light source assemblies 54 are connected in a series
configuration. Light source assemblies 56 are connected to the
series-connected light sources 54 as shown in FIG. 7.
[0075] Light source assemblies 56 includes a bypass resistor 58,
optional current limiting resistor 60, light source 62, which in
this embodiment is an LED, and diode 64. Light source assembly 56
may also includes a lamp holder (not shown), similar to the ones
described above.
[0076] Light source assemblies 54 includes a bypass resistor 58,
optional current limiting resistor 60, and light source 62 or light
source 66. In this embodiment, light source 62 is an LED chip, and
light source 66 is a "blinking" LED that incorporates a chip that
turns the LED on and off for a blinking or flashing effect.
Operation of light source 66 is independent of the other light
sources 62 due to the bypass resistor 58. Light source assembly 54
may also includes a lamp holder (not shown), similar to the ones
described above. Circuit 50 may utilize more than one blinking LED
66, per circuit, or may only include blinking LED 66 as its light
source.
[0077] In this embodiment, diodes 64 provide full-wave rectified
power to light source assemblies 54, causing light sources 62 and
66 of light source assemblies 54 to remain lit throughout most of
the AC power cycle. Light source assemblies 56 receive partial
rectification due to the particular configuration of FIG. 7,
causing light sources 62 of light source assemblies 56 to be
powered throughout approximately half the AC power cycle.
[0078] When light source 66 is a blinking LED chip as shown in FIG.
7, current is periodically interrupted to the LED on the chip.
Without bypass resistors 58, this would cause all light sources in
light string 50 to lose power due to an interruption of current
flowing through the series-connected circuit. However, bypass
resistor 28 allows current to continue flowing, maintaining power
to other light sources 62 and 66. Under normal operation, light
source 66 will cause its LED to blink on and off, creating a
twinkling effect, while other light sources 62 remain powered and
lit. The use of multiple light sources 66 in a light string 50
creates a desirable twinkling effect as light sources 66 turn on
and off, while light sources 62 remain lit.
[0079] In another embodiment, Light source 66 may be a multi LED
chip configuration, programmed to change the light output color of
the light source. Alternate embodiments may use a light source 66
where the bypass device 80 is an electronic circuit, or integrated
circuit across the LED leads inside or outside of the epoxy
housing/lens.
[0080] FIG. 8 illustrates another embodiment where, a resistive
bypass circuit 70 utilizes full-wave rectification to provide power
to all light sources 62 and 66. Resistive bypass circuit 70
includes an AC power source 72, full-wave rectifier 74 with
optional filter capacitor (not shown), main current limiting
resistor 78, bypass resistors 80, light sources 66 and 62.
Full-wave rectifier 74 includes four diodes 76. Full wave rectifier
74 may optionally employ one diode 76, and a sufficiently sized
filter capacitor to simulate full wave rectification. The AC power
source 72 may be any source voltage.
[0081] In this embodiment, full-wave rectifier 74 provides DC power
for bypass circuit 70. Main current limiting resistor 78 limits the
total amount of current flowing through circuit 70 and is sized
partially based on the number of light sources 62 and 66. The use
of a single current limiting resistor 78 rather than multiple
current limiting resistors simplifies design and manufacturing
efforts, but may optionally be manufactured with multiple current
limiting resistors as described in the embodiments above. Lights
source 66 in the form of blinking LED chips, along with bypass
resistors 80 create a twinkling effect when embodied in a light
string. The size of bypass resistor 80 depends on the electrical
characteristics of light source 66, but in one embodiment may be
300 to 600 ohms. In some embodiments, bypass resistor 80 may only
be used in conjunction with light sources 66, and not with light
sources 60. This configuration would enable the twinkling effect,
but would eliminate the bypass function at light sources 62.
[0082] Another embodiment is the use of circuit 70 in a DC-supplied
circuit, such that full wave rectifier 74 is not required.
Additional embodiments of circuit 70 are configured in a
series-parallel configuration. In another embodiment, light source
66 may be a multi LED chip configuration, programmed to change the
light output color of the light source.
[0083] FIG. 9 depicts a decorative lighting sculpture 90 that
includes an optional power plug 91, wires 98, optional connectors
96, main rod 92, branches 94, wires 100 and light source assemblies
102. Power plug 91 may be connected in one embodiment to a 45 VDC
to 50 VDC class 2 transformer with an output of 1.2 A, though other
voltage ranges and power sources may be used. Alternatively, light
sculpture 90 may not include power plug 91 and may be directly
connected a power source. Light source assemblies 102 may be
similar in configuration to the other light source assemblies
described above, utilizing incandescent bulbs, LEDs, or other light
sources configured in parallel with a bypass resistor.
[0084] In alternate embodiments, the bypass resistor may be
replaced by bypass circuits utilizing transistors or other
electronic active circuits.
[0085] The circuits and light strings of the present invention as
applied to artificial trees, wreaths, garlands, and other
artificial greenery, or alternatively to medium to large decorative
products, such as stars, figures, icons and other decorative
products provide a number of advantages. Replacing light strings
due to light sources that have failed on a light string that is
attached to an artificial tree or other decorative product, can be
a difficult task since the string is not easily removed from the
tree or products and the use of electric testers is not practical
due to the fields such products produce with the volumes of wires
and optional metal support structures. The bypass circuits and
light sets described herein ensure that the light string will
continue to remain lit even in the event of a light source failure,
meaning that the entire light string does not have to be removed
from the tree or decorative product. The combination of circuits,
light strings and tree make a reliable, convenient lighted green
goods system. FIGS. 10-12 depict some of the artificial trees used
in such a lighted green goods system.
[0086] FIG. 10 shows one version of an artificial tree 140 that
includes a tree trunk 148, branches 142, branch mains 144, and
sub-branches 146. Artificial tree 140 may be constructed of a
combination of many materials as described above. In this
embodiment, artificial tree 140 is constructed primarily of painted
metal, or in another embodiment made primarily of plastic, or a
combination of plastic and metal.
[0087] FIG. 11 shows another version of an artificial tree, 140'.
Artificial tree 140' includes tree trunk 148', branches 142',
branch mains 144', sub-branches 146' and needles 149. Needles 149
are commonly derived from PVC, nylon, and/or PE and may be green in
color to make artificial tree 140' appear to be an evergreen or
pine tree. In another embodiment it may use white needles and
branches for different aesthetics.
[0088] FIG. 12 light string, such as light string 30, 40, 50, 70,
or a combination thereof, attached to branches 142 of tree 140 to
form a pre-lit tree system 200. Light strings 30, 40, 50, 70, or
other embodiments of the present invention, may be similarly
attached to trees 140'. Light string 30, 40, 50, 70 is shown
attached to tree 140 via clips 150. Clip 150 may include but are
not limited to C clips, snap lock clips, and wire ties.
[0089] FIGS. 13 and 14 depict the present invention in the form of
flexible lighting, or rope lighting. Flexible lighting 300 as
depicted in FIG. 13 includes an outer encasement 302, end cap 304,
power cap 306, power cord 308, power plug 310, and one or more
bypass circuits 312. Flexible lighting 300 may operate on 120VAC,
which is transmitted through power plug 310 and power cord 308,
though other voltages may be used, and the input may be rectified
or DC. Outer encasement 302 is typically made of a PVC material,
and houses bypass circuit 312. Power cap 306 assists in attaching
power cord 308 to bypass circuit 312 and may attach to outer
encasement 302 by any number of known methods.
[0090] Bypass circuits 312 are series circuits and each bypass
circuit 312 is connected in parallel with the other. Bypass circuit
312 includes a plurality of light sources 314 electrically
connected in parallel with bypass resistors 320. Light sources 318
may be incandescent bulbs, LEDs, or other light sources. As
described in previous embodiments, bypass resistor 320 may be
replaced with another active circuit device. Bypass circuit 312 may
also include conductors 314 and 316 which extend the length of
flexible lighting 300 and provide power to the bypass circuits 312
when more than one circuit 312 is employed.
[0091] Operation of flexible lighting 300 is similar to those
embodiments described above. During normal operation, current flows
through both light source 318 and bypass resistors 320. If light
source 318 fails, the entire bypass circuit 312 current flows
through bypass resistor 320, allowing flexible lighting 300 to stay
lit.
[0092] FIG. 14 depicts a similar flexible lighting system that
relies on LEDs, rather than incandescent bulbs. Flexible lighting
400 as depicted in FIG. 14 includes an outer encasement 402, end
cap 404, power cap 406, power cord 408, power plug 410, and one or
more bypass circuits 412. Flexible lighting 400 may operate on
120VAC, which is transmitted through power plug 410 and power cord
408, though other voltages may be used, and the input may be
rectified or DC. Outer encasement 402 is typically made of a PVC
material, and houses bypass circuit 412. Power cap 406 assists in
attaching power cord 408 to bypass circuit 412 and may attach to
outer encasement 402 by any number of known methods.
[0093] Bypass circuits 412 are series circuits and each bypass
circuit 412 is connected in parallel with the other. Bypass circuit
412 includes a plurality of LEDs 414 electrically connected series
with resistors 419. Series connected LEDs 414 and resistors 419 are
electrically in parallel with bypass resistors 420. Light sources
418 may be LEDs, or other light sources. As described in previous
embodiments, bypass resistor 420 may be replaced with another
active circuit device. Bypass circuit 412 may also include
conductors 414 and 416 which extend the length of flexible lighting
400 and provide power to the bypass circuits 412 when more than one
circuit 412 is employed. The number or location of resistors 419 in
each circuit 421 may vary based on circuit requirements, with some
bypass circuits 412 not including a resistor 419. In other
embodiments, resistor 419 may be located external to circuit 421,
and in line with circuit Bypass circuit 412.
[0094] Operation of flexible lighting 400 is similar to those
embodiments described above. During normal operation, current flows
through both light source 418 and bypass resistors 420. If light
source 418 fails, the entire bypass circuit 412 current flows
through bypass resistor 420, allowing flexible lighting 400 to
remain lit.
[0095] Other embodiments of flexible lighting 300 and 400 may
incorporate twinkling, flashing and color changing properties as
previously described above. It is desired to utilize incandescent
bulbs with the embodiment of FIG. 1. In order to make the resistive
bypass set 10 function with modern, high temperature materials, it
was needed to reduce the wattage of the bulbs to at least 0.25 W
(standard bulbs in the industry are the 0.30 W bulb). It is
preferable to use bulbs of 0.20 Watts. Sets using 0.25 W bulbs are
on the edge of passing ANSI/UL standards, a critical condition for
placing the resistive bypass set 10 in the marketplace. The 0.20 W
bulbs, on the other hand, safely allows the set to operate and
readily meet ANSI/UL standards, however, either 0.25 W or 0.20 W
bulbs could be used.
[0096] In addition, the resistor sets with LED sources can also be
employed, and as those typically operate at much lower current (20
mA) drawing approximately 0.08 W, those allow for very cool
operation of the resistor bypass circuit. Additional embodiments
may use a higher power LED or multiple LEDs connected in parallel
across the resistive element.
[0097] Both of these lighting changes (lower wattage/higher
brightness bulbs, and LEDs) were not anticipated, or contemplated
by Fisherman, therefore only restricting it to flasher bulbs, and
the use in such a set where the bulbs are never fully off.
[0098] In addition, this allows our resistor bypass set to operate
as a twinkling set by inserting a flasher bulb into any circuit.
Flasher bulbs are bulbs where the bimetallic strip heats, and open
circuits the bulb, where a normal holiday light set that creates a
twinkling effect has to use twinkling bulbs, where when the
bimetallic strip is heated by the filament, it shorts out the bulb,
allowing the remaining bulbs to light, however, in such sets where
the bulbs short, ANSI/UL does not allow for such constructions in
flexible (rope) lighting. However, in the resistor bypass set, use
of a flasher bulb is not restricted, nor does it pose any
additional safety concerns, as when the flasher bulb open circuits,
it allows the resistor bypass set to work as it would normally, and
actually reduces the current to the remaining bulbs, allowing to
run cooler, vs. the twinkle bulb set where it operates hotter when
one or more bulbs is in the shorted condition.
[0099] The resistor bypass set also has the advantage providing a
shunting circuit, as ANSI/UL standards do not allow for shunts that
short circuit the bulb in rope (flexible) lighting, as the bulbs
are not replaceable, and shorts caused by shunt wires in or out to
the bulb would create an unsafe condition as more and more bulbs
burn out. A shunt wire inside the bulb to allow the current to
continue flowing, as those bulbs create short circuits, further
dividing the input voltage by the remaining bulbs, increasing the
power drop across each bulb, thereby increasing the surface
temperature of the bulb, and causing the subsequent bulb to burn
out faster, and this repeated action causing the bulbs to become
very hot, where as the resistor bypass set operates such that every
bulb failure, places a higher resistance into the set than the bulb
it replaces, causing the remaining bulbs to proportionally dim,
causing them to increase their life, and run cooler. However, the
resistor could be sized such hat the current is not reduced, and
may remain relatively constant.
[0100] In addition to decorative lighting, the bypass circuits of
the present invention may also be used in general lighting
applications including portable lighting, auto lighting, traffic
lights and the like.
[0101] The invention addresses many of the deficiencies and
drawbacks previously identified. The invention may be embodied in
other specific forms without departing from the essential
attributes thereof; therefore, the illustrated embodiments should
be considered in all respects as illustrative and not restrictive.
The claims provided herein are to ensure adequacy of the present
application for establishing foreign priority and for no other
purpose.
* * * * *